Personally, i do it something like this:

Fill shock body

Place (cut) diaphram on top of body

Screw cap on half way

Push piston up, until threads are in the region of 5mm from the bottom of the shock

Screw cap all the way down

That way, the area you talk of that you have filled with air, is now filled with oil.

Those purple caster blocks are sick! I need to get me some:p:p:p:thumbsup::thumbsup::thumbsup:

I build my shocks the same as he did in the guide. My shocks have no air at all, and dont leak one bit! And there smoooooooth as can be. I love it!:thumbsup::woot:

What ball cup lengths are people using?

full length ones cut to 3/4, front and back

Full ball cup = about 19mm

so that would mean you are using 14.25mm ball cup?

never measured them but sounds about right,

Why not just buy the right part of Schumacher? Cutting isn't accurate enough for my liking.

didnt think schuy made them 3/4
length chris??

Yes please tell us the part number

http://www.jespares.com/faq/6-guides...-rebuild-guide

updated link